BS EN Welding Book

Typical Welding
Procedure
Specifications for
Structural Steelwork
BCSA Publication No. 50/09
Typical Welding
Procedure
Specifications for
Structural Steelwork
The British Constructional

Steelwork Association Limited
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Acknowledgements
This publication has been produced with the special assistance of:
Mr Jeff Garner - BCSA
Mr Johann Krancioch - Severfield-Rowen plc
Mr Richard Thomas - Rowecord Engineering Ltd
Dr David Moore - BCSA
Mr David Brown - SCI
TYPICAL WELDING PROCEDURE SPECIFICATIONS FOR STRUCTURAL STEELWORK
Contents
1 Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Typical Welding Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Basis of the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 Qualification of Welding Procedure Specifications to BS EN ISO 15614-1 . . . . . . . . . . . . . . . . . . . . .
3.4 How to use this document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
6
6
6
7
4 Preliminary Welding Procedure Specifications (pWPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

4.1 pWPS sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5 Qualification of Welding Procedure Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Fillet Welds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 Butt Welds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4 Examination and testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
25
25
25
26
6 Typical Welding Procedure Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

6.1 Typical WPS - contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Appendix A - Calculation of preheating requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Appendix B - Metal-arc Active Gas shielded (MAG) welding (Process 135) . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Appendix C - Typical Welding Procedure Qualification Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
1 Foreword
This publication has been prepared with the aim of simplifying and
standardising welding procedures used in structural steelwork.
The need for such a document was first identified some years ago
by a group of welding engineers, steelworks contractors,
metallurgists and industry experts and a draft document was
produced outlining how this might be achieved and the range of
variables which typically needed to be considered. This publication
draws on the wealth of experience, knowledge and work put in to
the early document and has been updated to reflect current welding
practice, standards and specifications.
This document contains 14 preliminary Welding Procedure
Specifications (pWPS) as defined in BS EN ISO 15614-1, and 40
partially completed Welding Procedure Specifications (WPS), called
typical WPS in this document. The pWPS have been identified as
those required to support the necessary welding procedure tests on
the route to qualifying the typical WPS. The typical WPS have been
chosen to cover the majority of WPS required for the welding of
structural steelwork for buildings and bridges. They cover weld types
ranging from simple fillet welds to the more difficult butt welds made
from one side, with backing.
To assist the user the weld types are placed in five categories where,
in general terms, the skill level required by the welder increases the
higher the category number. The categories are as follows:
Category 1: Fillet welds only (PA, PB positions)
Category 2: Fillet welds only (PA, PB and PF positions)
Category 3: Fillet welds (PA, PB positions); butt welds made from
two sides in the PA position
Category 4: Fillet welds (PA, PB and PF positions); butt welds made
from two sides in the PA position
Category 5: Fillet welds (PA, PB and PF positions); butt welds made
from two sides or with permanent backing in the PA, PC
and PF positions
Depending on contract requirement and welder competence,
a steelwork contractor may select the appropriate range of weld
types to be approved and the associated pWPS. More details on the
choice of pWPS are given in Section 3.3 How to use this document.
The five categories are recommendations; a steelwork contractor is
at liberty to choose a different selection of pWPS resulting in a
different range of approved WPS.
2 Scope
This document is intended for use by steelwork contractors, welding
engineers and inspectors, and those actively involved in welding and
welding technology. Familiarity with BS EN ISO 15614, BS EN 287,
and the welding principles contained in BS EN 1011 is required.
Structural capacity checking and weld inspection are not addressed
in this document.
This document contains 14 preliminary Welding Procedure
Specifications (pWPS) written in accordance with the requirements
of BS EN ISO 15609-1. They cover the welding of plate and rolled
sections up to 25mm thick in carbon manganese structural steels to
BS EN 10025, with a maximum carbon equivalent value (CEV) of
0.45 (1) (see BS EN 1011-2 Clause C.2.1). The maximum combined
thickness is limited to 75mm.
The welding process is solid wire partly mechanised Metal-arc Active
Gas (MAG), process 135 in BS EN ISO 4063. It is assumed that
preparation, control and use of a suitable consumable will achieve a
hydrogen content of 5ml/100g or below in the deposited weld metal
i.e. Scale D in BS EN 1011-2, Table C.2. In order to achieve the
required hydrogen content, the steelwork contractor should ensure
that consumables are stored and used in accordance with
manufacturers' recommendations - i.e. they should be kept clean,
dry and free from contamination.
The welding parameters proposed in the pWPS are designed to
produce welds which meet the mechanical requirements of BS EN
10025 steel grades up to and including S355J2; with a minimum
Charpy impact value of 27J at -20C.
(1)
Restriction on the CEV, material thickness and hydrogen Scale D

results in procedures which do not require pre-heating. Appendix A
demonstrates how this has been achieved, and the effect of
alternative hydrogen scales.
This document also contains 40 partially completed WPS which
have been prepared for general application in the welding of
structural steelwork for buildings and bridges. The partially
completed WPS require welding procedure tests and Welding
Procedure Qualification Records (WPQR) to be completed before
they may be used.
When qualified in accordance with the requirements of BS EN ISO
15614-1, some of the pWPS in this document would qualify parent
metal thicknesses up to and including 30mm. However, using the
welding parameters suggested, a thickness limitation of 25mm is
applied so as to avoid the requirement for preheating. Should a
steelwork contractor choose to develop Welding Procedure
Specifications (WPS) outside the scope of this document i.e.
utilising the full extent of approval, the requirements for preheating
must be reviewed.
The proposed details may not be appropriate in all circumstances
(such as arrangements with a high degree of restraint, or butt welds
without backing in relatively thin materials) nor is the performance of
welds completed in accordance with these details guaranteed.
Vertical-down (PG) and overhead (PE butt and PD fillet) welding are
excluded from the procedures in this document.
The WPS in this document are based on using steel with a CEV of 0.45, since this is the maximum allowable in BS EN 10025 for grade S355 steels < 30mm thick.
However, reputable steel makers typically supply products with CEV's lower than the specified maximum. In light of this, when developing WPS outside the scope
of this document, a steelwork contractor may wish to consider purchasing steel with a CEV lower than the maximum to accommodate a greater thickness range
without the requirement for preheating. Specifying a maximum CEV of 0.43 may not be unreasonable for S275 and S355 grade steels.
3 Typical Welding Procedures

3.1
Introduction
Steelwork contractors have, traditionally, tended to develop and

qualify welding procedures on a contract by contract basis as a
specific need arises. Whilst this has resulted in an extensive range of
available welding procedures within the industry, there is evidence to
suggest that this has resulted in a considerable amount of
duplication and, perhaps more importantly, unnecessary cost.
A careful assessment of workshop welding activities at a typical
steelwork contractor would identify a limited number of variables and
the potential for adopting a rationalised range of welding
procedures. The advantages of which would be as follows:
a broad range of welds may be covered by a few carefully

prepared procedures
these procedures may be qualified using a limited range of

procedure qualification tests
standard weld preparations in terms of included angle, root

face and root gap considerably improve the probability of
achieving the required weld quality
when the weld preparations are standard, the chances of

identifying incorrect preparations before fabricating and
welding is improved
use of standard welding conditions generates consistent

quality and can give greater control of production costs
This document is aimed at providing the framework for a steelwork

contractor to develop and qualify rationalised welding procedures,
appropriate to its range of welding activities, in accordance with the
requirements of BS EN ISO 15614-1.
3.2
Basis of the system
Qualification of Welding Procedure

Specifications to BS EN ISO 15614-1
This document is intended to assist steelwork contractors to develop

qualified Welding Procedure Specifications (WPS) for use in the
fabrication workshop. The method of qualification is by welding
procedure tests to BS EN ISO 15614-1.
In general, qualification of a WPS to BS EN ISO 15614-1 requires the
steelwork contractor to:
1. Determine the range of weld joints to be qualified (i.e. thickness,
configuration etc.)
2. Prepare a preliminary welding procedure specification (pWPS) which is assumed to be adequate. These are prepared in
accordance with BS EN ISO 15609-1, using previous experience
and the general fund of knowledge of welding technology.
3. Carry out a welding procedure test to prove the feasibility of the
procedure described in the pWPS. Details of the test pieces and
the necessary destructive tests and non-destructive
examinations are described in BS EN ISO 15614-1.
4. Prepare a welding procedure qualification record (WPQR)
detailing the actual welding parameters and other relevant data
from the welding procedure test together with the results of the
destructive testing and non-destructive examination.
5. Use the WPQR data to prepare Welding Procedure
Specifications (WPS) within the ranges of qualification given in
BS EN ISO 15614-1.
Figure 3.1 shows how these steps relate to the information given in
this document:
Information from
BS EN ISO 15614-1
this document
The system of preliminary Welding Procedure Specifications (pWPS)

and partially completed WPS contained in this document has been
developed to meet the requirements of the majority of workshop
fabrication for steel buildings and bridges.
(1)
Develop a preliminary
welding procedure
specification (pWPS)
Choose the appropriate

pWPS given in
Section 4
The welding details have been developed for the standard grades of
structural steels, S275 and S355 up to and including sub-grade J2,
using the Metal-arc Active Gas (MAG) process. Joint configurations
and welding positions have been chosen to meet the majority of
practical requirements.
(2)
Complete a welding
procedure test
Details of required test

pieces given in
Section 5
(3)
Complete a welding
procedure qualification
record (WPQR)
Example WPQR
given in
Appendix C
(4)
Prepare Welding Procedure
Specifications (WPS)
based on the (WPQR)
Typical completed
WPS given in
Section 6
The joint details have been so arranged such that up to a specified

maximum combined thickness, (the sum of the parent metal
thicknesses averaged over a distance of 75mm from the weld line)
preheat is not required. This assumes that the shop floor preparation
and control is sufficient to eliminate hydrogen-generating
contaminants such as oil, grease, rust and condensation, to reduce
the possibility of hydrogen-induced cracking. The maximum material
thickness is limited to 25mm and the maximum combined thickness
to 75mm.
Guidance on the Metal-arc Active Gas process is given in
Appendix B
3.3
Figure 3.1 Method of qualifying welding procedures to

BS EN ISO 15614-1
3.4
How to use this document
A steelwork contractor using this document should:

1. Decide which weld types best suit its welding activities from the
five recommended categories given in Table 3.1. This decision
should generally be based on product range, contract
requirements, welder competence, anticipated future
requirements and whether or not the steelwork can typically be
turned so that all welding is carried out in the flat (PA) or
horizontal vertical (PB) position. If the steelwork cannot be
turned, a higher category will be required to cover the positional
limitations in BS EN ISO 15614-1.
The degree of difficulty in producing satisfactory welds
increases with the higher the category number selected. Equally,
the anticipated need for the additional weld types decreases.
For example, whilst all steelwork contractors will require
approval for fillet welds, fewer joints are welded as single sided
butt welds with backing.
Category pWPS
1
01p, 02p, 03p, 04p
3. Collate and review the mechanical and non-destructive testing

results provided by the test laboratory and, if acceptable,
complete the appropriate Welding Procedure Qualification
Record (WPQR) documentation to support the procedure tests.
Depending on the contractual arrangements, the WPQR
documentation might be completed by either the steelwork
contractor's Responsible Welding Coordinator or the examiner /
examining body. An example of a completed WPQR is given in
Appendix C.
4. Using Table 6.1 in Section 6, select the relevant partially
completed WPS(s) qualified by the chosen category and
complete them by, if necessary, revising the welding parameters
and adding the appropriate WPQR reference number. A number
of WPS may be prepared based on one or more WPQR,
according to the ranges permitted in BS EN ISO 15614-1.
Qualification Range
Fillet welds only in PA and PB
positions
01p, 02p, 03p, 04p,
Fillet welds only in PA, PB and
05p, 06p, 07p, 08p
PF positions
01p, 02p, 03p, 04p
Fillet welds in PA and PB

positions
09p, 10p
Two sided butt welds in the

PA position
01p, 02p, 03p, 04p,
Fillet welds in PA, PB and PF
05p, 06p, 07p, 08p
positions
09p, 10p

PA position
01p, 02p, 03p, 04p,
Fillet welds in PA, PB and PF
05p, 06p, 07p, 08p
positions
09p, 10p

PA position
11p, 12p, 13p, 14p
Butt welds with backing in PC

and PF positions
Table 3.1 Category, pWPS and qualification range
2. Using the pWPS identified within the chosen category in Table

3.1, carry out welding procedure test pieces witnessed by an
appropriate examiner / examining body and have these tested in
accordance with the requirements given in BS EN ISO 15614-1.
The pWPS may be modified to reflect individual workshop
practice.
4 Preliminary Welding Procedure

Specifications (pWPS)
4.1
pWPS sheets
ensure that all fusion faces are clean and free from oil, grease,
scale and other contaminants which may be detrimental to the
welding process.
For consistency and ease of use, the format of the pWPS, and
subsequent WPS, is based on the example given in Annex A of BS
EN ISO 15609-1. Section 4 contains 14 preliminary Welding
Procedure Specifications (pWPS). Table 3.1 in Section 3 shows the
selection of pWPS which, when completed, tested, examined and
qualified, allow the completion and provide qualification of the WPS
contained in Section 6. The pWPS are placed in categories based
upon level of complexity and, as such, the steelwork contractor may
elect to qualify whichever category it considers most appropriate for
its product range.
If a steelwork contractor's normal procedure is to weld materials which

have been coated with a prefabrication primer, the test pieces used to
qualify the Welding Procedure Specification (WPS) should be coated
accordingly. It should be noted that welding material coated in this
way may invalidate the assumption that Scale D hydrogen levels will
be achieved (see Pre-heat temperature on page 10). If welding
pre-coated material, hydrogen levels in the deposited weld metal
should be determined by test in accordance with BS EN ISO 3690.
The details given on the pWPS are described in the following sections.
Parent material designation
Location
Stating 'Workshop' or 'Site' will generally suffice unless the steelwork
contractor operates from a number of different workshop / site
locations then the site reference should be specified.
WPS number
Procedures are presented in numerical order followed by the letter
(p) to signify that they are preliminary and require qualification.
WPQR
The WPQR number is not applicable since the welding procedure is
only at the preliminary stage and, as such, is unqualified.
Manufacturer
The procedures state 'to be confirmed'. When a manufacturer
chooses to qualify a particular pWPS then the manufacturer's own
name, address etc. should be entered here.
BS EN 10025 S355J2 steel with a maximum Carbon Equivalent

Value (CEV) of 0.45 is specified for the pWPS, as successful tests in
this material will also cover steels of lower yield strength and the subgrades JR and J0.
Material thickness
The material thickness specified is the actual thickness to be used
during qualification of the pWPS.
Outside diameter
Each pWPS states 'not applicable' since they are all designed for use
on plate.
Welding position
Welding positions are described by the BS EN ISO 6947
designation. The correspondence between these and the American
Welding Society (AWS) designations is shown in Table 4.1. The
pWPS in Section 4 cover welding in the PA, PB, PC and PF positions.
Welder's name
Each of the pWPS states 'to be confirmed'. Whilst there is typically no
requirement to specify the welder's name on a WPS, it may be
prudent to do so on a pWPS since the welder who satisfactorily
undertakes the welding procedure qualification test is automatically
qualified within the range of qualification given in BS EN 287.
Weld Type Position

Butt
Welding process
On each pWPS the welding process is given its numeric reference
number according to BS EN ISO 4063 along with its standard
abbreviation (i.e. 135 - MAG)
Joint type
Each pWPS specifies the type of joint and whether it is to be welded
single or double sided, with or without backing etc.
Method of preparation and cleaning

Each pWPS specifies thermal cut and or grinding, wire brush and
degrease if required. Thermal cut could be plasma, laser or oxy-fuel
gas cutting. The method of preparation should be that most suited
to the steelwork contractor's environment, equipment and working
practices. Whichever method is selected, care should be taken to
Fillet
Designation
BS EN
AWS
Flat
Horizontal
Vertical downwards
Vertical upwards
PA
PC
PG
PF
1G
2G
3G
3G
Overhead
PE
4G
Flat
Horizontal vertical
Vertical downwards
Vertical upwards
Horizontal overhead
PA
PB
PG
PF
PD
1F
2F
3F
3F
4F
Table 4.1 Comparison of BS EN and AWS weld position

designations
Figure 4.1 Illustrates the designated positions for plates and open
sections
Butt Welds:
Joint design
A sketch of the joint preparation is given on each pWPS. This
typically includes such items as the material dimensions, root gap,
root face, included angle etc. The preparations indicated generally
conform to the requirements of BS EN ISO 9692-1: 2003.
Welding Sequence
PA Flat
PC Horizontal
A sketch of the welding sequence is given. This shows the intended

deposition sequence, run number(s) and any dimensional
requirements.
Run
Each weld run is given a number that is linked to the welding
sequence sketch.
Process
The MAG process is identified as process 135 in BS EN ISO 4063.
PE Overhead
Size of filler metal

The wire electrode size stated in the pWPS is that considered most
appropriate to cover the proposed range of material thicknesses. If
an alternative wire electrode size is required to suit a particular
environment (i.e. where the work is predominantly on thin sections or
where extensive positional welding is envisaged) the welding
procedure qualification test should be undertaken using a wire
diameter most suited to that application.
PG Vertical Downwards
PF Vertical Upwards
Welding parameters
Fillet Welds:
PA Flat
PB Horizontal Vertical
The welding parameters, travel speeds, wire feed rates etc. given on
the pWPS are taken from previously qualified welding procedures
and are thus considered appropriate for the joint configurations and
material thicknesses they are assigned to. The specified heat inputs
are calculated using the formula given in BS EN 1011-1. It is
recognised however, that alternative welding parameters and
conditions could be used to achieve successful welding. In view of
this, when carrying out welding procedure qualification tests, the
steelwork contractor should not be precluded from selecting
alternative parameters and welding conditions to suit working
practices that are already established. The welding procedure
qualification test should be based on a revised pWPS.
Filler metal classification and trade name
PD Horizontal Overhead
The consumable classification given in the pWPS is BS EN ISO

14341: G3Si1. This is the equivalent classification given in the old BS
2901-1 Type A18. Whilst not a specific requirement of BS EN ISO
15614-1 for solid wires, it is recommended that the consumable
trade name should be confirmed by the steelwork contractor during
the procedure qualification test.
Any special baking or drying

There are no special drying or baking requirements for solid wires.
They should, however, be kept clean, dry and stored in accordance
with manufacturers' recommendations.
PG Vertical Downwards
PF Vertical Upwards
Figure 4.1 Welding positions according to BS EN ISO 6947
10
Gas/flux: - shielding / backing
Time, temperature, method
In accordance with as BS EN ISO 15614-1, qualification given to the

shielding gas used in the welding procedure test is restricted to the
symbol of the gas according to BS EN ISO 14175. The shielding gas
adopted in the pWPS, BS EN ISO 14175 M26 (Argon / 20%CO2 /
2%O2), is a general purpose gas composition commonly used for
the range of thicknesses proposed in the pWPS. However, other
similar compositions could be used. The chosen gas composition
Each pWPS states not applicable since this relates to the control of
parameters for the post-weld heat treatment.
should be specified on the pWPS and used in the welding procedure

qualification test.
Each pWPS contains additional general information relevant to

successful implementation of the procedure. It typically includes the
recommended nozzle diameter on the welding torch, the method for
checking the interpass temperature, any specific in-process nondestructive testing requirements and the required weld finish.
Shielding gas flow rate

The pWPS give a range of shielding gas flow rates typical of those
normally used with the proposed welding parameters.
Tungsten electrode type / size

Each pWPS states 'not applicable' since this is not relevant to the
MAG process.
Details of back gouging / backing

The term back gouging is used to cover all means of removing
material from the second side of a welded joint back to sound metal.
It includes all forms of gouging techniques i.e. arc/air, plasma,
grinding etc. In those pWPS where back gouging is required, it is
recommended that some form of NDT is applied before completing
the second side weld (i.e. Magnetic particle inspection or liquid
penetrant testing).
Preheat temperature
The welding procedures within this document are limited to a
maximum material thickness of 25mm (75mm maximum combined
thickness) to eliminate the requirements for preheating. It should be
noted, however, that this is based on the following assumptions:
a workpiece temperature of at least 0C
the control applied to the weld preparation, welding process

and consumables will achieve a diffusible hydrogen content
of 5 ml/100 g or below (i.e. scale D in BS EN 1011 Table C.2)
in the deposited weld metal.
Combined thicknesses greater than 75 mm are outside the scope of

this document.
Interpass temperature
For certain types of steel too high an interpass temperature may
have an undesirable affect on notch toughness in the heat affected
zone, or may cause an alteration of properties produced by a
previous heat treatment of the steel.
The maximum interpass temperature stated on the pWPS (250C) is
based on recommended good practice for Group 1 type steels.
However, in accordance with BS EN ISO 15614-1, the upper limit of
approval is the nominal maximum interpass temperature reached
during the welding procedure test.
Post-weld heat treatment and / or ageing

Each pWPS states not applicable. Post-weld heat treatment on
Group 1 type steels used in buildings and bridges is generally not
required and, as such, is outside the scope of this document.
11
Heating and cooling rates

Each pWPS states not applicable since this relates to the control of
parameters for the post-weld heat treatment.
Other information
For manufacturer
Each pWPS states 'RWC's Signature'. When a steelwork contractor
chooses to qualify a WPS, the Responsible Welding Coordinator
(RWC) is required to sign and date the pWPS so as to verify that the
proposed welding parameters are considered suitable and that the
subsequent range of qualification will be adequate for the intended
future application.
For examiner / examining body

Each pWPS states 'to be confirmed'. The examiner / examining body
who witnesses the welding procedure qualification test should sign
and date this once the pWPS is revised to reflect the actual welding
parameters used in the tests; at which time the pWPS will become
part of the documentation used to support the WPQR.
preliminary Welding Procedure Specification (pWPS)

Location: Workshop
Manufacturers Welding Procedure Specification No: 01p
WPQR: N/A*
Manufacturer: To be confirmed
Method of Preparation and Cleaning:

Thermal cut and / or grinding, wire brush and degrease if required
Parent Material Designation:
BS EN 10025-2: S355 J2 (Max CEV = 0.45)
Material Thickness: 10mm
Outside Diameter: N/A
Welding Position: PB (Horizontal - Vertical)
Welders Name: To be confirmed

Welding Process: 135 (MAG)
Joint Type: Fillet Weld (Single or Double Sided)
Joint Design
Welding Sequence
10 mm
z6
< 1mm
10 mm
Dimension z = Fillet weld leg length in mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
135 (MAG)
1.2
270 - 290
29 - 31
DC +ve
7.5 - 8.3
320 - 340
1.1 - 1.3
Filler Metal Classification & Trade Name
BS EN ISO 14341: G3 Si1 (Trade name to be confirmed)
Any Special Baking or Drying
Stored in accordance with manufacturers recommendations
Gas/Flux: - Shielding / Backing
Argon / 20% CO2 / 2% O2
Shielding Gas Flow Rate
15 - 18 L/min
Tungsten Electrode Type / Size
N/A
Details of Back Gouging / Backing
N/A
Preheat Temperature
0C Minimum
Interpass Temperature
N/A
Post-Weld Heat Treatment and / or Ageing
N/A
Time, Temperature, Method
N/A
Heating & Cooling Rates
N/A
Other Information:
Nozzle diameter = 16mm.

Weld finish to be left as-welded.
For Manufacturer:
RWCs Signature
*N/A = Not Applicable
For Examiner / Examining Body:

To be confirmed
12

Location: Workshop
WPQR: N/A*

BS EN 10025-2: S355 J2 (Max CEV = 0.45)

Joint Design
Welding Sequence
25mm
z6
< 1mm
25mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
135 (MAG)
1.2
290 - 310
29 - 31
DC +ve
8.3 - 9.0
300 - 330
1.2 - 1.5
Argon / 20% CO2 / 2% O2
15 - 18 L/min
N/A
N/A
Preheat Temperature
0C Minimum
N/A
N/A
N/A
N/A
Other Information:

For Manufacturer:
RWCs Signature
13

To be confirmed

Location: Workshop
WPQR: N/A*

BS EN 10025-2: S355 J2 (Max CEV = 0.45)

Joint Type: Fillet Weld - Multi-run (Single or Double Sided)
Joint Design
Welding Sequence
10mm
z 10
< 1mm
10mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
135 (MAG)
1.2
270 - 290
29 - 31
DC +ve
7.5 - 8.3
320 - 340
1.1 - 1.3
2-3
135 (MAG)
1.2
270 - 290
29 - 31
DC +ve
7.5 - 8.3
340 - 380
0.9 - 1.3
Argon / 20% CO2 / 2% O2
15 - 18 L/min
N/A
N/A
Preheat Temperature
0C Minimum
250C Maximum
N/A
N/A
N/A
Other Information:

Interpass temperature shall be checked using a contact thermometer or temperature indicating crayon.
For Manufacturer:
RWCs Signature

To be confirmed
14

Location: Workshop
WPQR: N/A*

BS EN 10025-2: S355 J2 (Max CEV = 0.45)

Joint Type: Fillet Weld Multi-run (Single or Double Sided)
Joint Design
Welding Sequence
25mm
z 10
< 1mm
25mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
135 (MAG)
1.2
290 - 310
29 - 31
DC +ve
8.3 - 9.0
300 - 330
1.3 - 1.5
2-3
135 (MAG)
1.2
290 - 310
29 - 31
DC +ve
8.3 - 9.0
310 - 330
1.2 - 1.5
Argon / 20% CO2 / 2% O2
15 - 18 L/min
N/A
N/A
Preheat Temperature
0C Minimum
250C Maximum
N/A
N/A
N/A
Other Information:

For Manufacturer:
RWCs Signature
15

To be confirmed

Location: Workshop
WPQR: N/A*

BS EN 10025-2: S355 J2 (Max CEV = 0.45)
Welding Position: PF (Vertical Upwards)

Joint Design
< 1mm
Welding Sequence
10mm
z6
10mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
135 (MAG)
1.2
160 - 180
19 - 21
DC +ve
4.6 - 5.3
120 - 140
1.0 - 1.5
Argon / 20% CO2 / 2% O2
15 - 18 L/min
N/A
N/A
Preheat Temperature
0C Minimum
N/A
N/A
N/A
N/A
Other Information:

For Manufacturer:
RWCs Signature

To be confirmed
16

Location: Workshop
WPQR: N/A*

BS EN 10025-2: S355 J2 (Max CEV = 0.45)

Joint Design
< 1mm
Welding Sequence
25mm
z6
25mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
135 (MAG)
1.2
190 - 200
19 - 21
DC +ve
5.1 - 5.5
120 - 140
1.3 - 1.6
Argon / 20% CO2 / 2% O2
15 - 18 L/min
N/A
N/A
Preheat Temperature
0C Minimum
N/A
N/A
N/A
N/A
Other Information:

For Manufacturer:
RWCs Signature
17

To be confirmed

Location: Workshop
WPQR: N/A*

BS EN 10025-2: S355 J2 (Max CEV = 0.45)

Joint Design
Welding Sequence
10mm
< 1mm
2
z 10
10mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
135 (MAG)
1.2
160 - 180
19 - 21
DC +ve
4.6 - 5.3
120 - 140
1.0 - 1.5
2-3
135 (MAG)
1.2
160 - 180
19 - 21
DC +ve
4.6 - 5.3
140 - 160
0.9 - 1.3
Argon / 20% CO2 / 2% O2
15 - 18 L/min
N/A
N/A
Preheat Temperature
0C Minimum
250C Maximum
N/A
N/A
N/A
Other Information:

For Manufacturer:
RWCs Signature

To be confirmed
18

Location: Workshop
WPQR: N/A*

BS EN 10025-2: S355 J2 (Max CEV = 0.45)

Joint Design
Welding Sequence
25mm
< 1mm
z 10
25mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
135 (MAG)
1.2
190 - 200
19 - 21
DC +ve
5.1 - 5.5
120 - 140
1.3 - 1.6
2-3
135 (MAG)
1.2
190 - 200
19 - 21
DC +ve
5.1 - 5.5
110 - 130
1.3 - 1.8
Argon / 20% CO2 / 2% O2
15 - 18 L/min
N/A
N/A
Preheat Temperature
0C Minimum
250C Maximum
N/A
N/A
N/A
Other Information:

For Manufacturer:
RWCs Signature
19

To be confirmed

Location: Workshop
WPQR: N/A*

BS EN 10025-2: S355 J2 (Max CEV = 0.45)
Welding Position: PA (Flat)

Joint Type: Single Vee Butt Weld
(full penetration, welded from both sides)
Joint Design
Welding Sequence
50 - 0 / +10
10mm
Side 1
3
2
1
4
Side 2
0 - 2mm
0 - 3mm
Grind back Side 2 to sound metal and MPI
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
135 (MAG)
1.2
220 - 240
26 - 28
DC +ve
5.5 - 6.2
250 - 270
1.0 - 1.3
2-4
135 (MAG)
1.2
270 - 290
29 - 31
DC +ve
7.5 - 8.3
300 - 320
1.1 - 1.4
Argon / 20% CO2 / 2% O2
15 - 18 L/min
N/A
Grind back to sound metal and MPI
Preheat Temperature
0C Minimum
250C Maximum
N/A
N/A
N/A
Other Information:

For Manufacturer:
RWCs Signature

To be confirmed
20

Location: Workshop
WPQR: N/A*

BS EN 10025-2: S355 J2 (Max CEV = 0.45)

(full penetration, welded from both sides)
Joint Design
Welding Sequence
50 - 0 / +10
15mm
Side 1
0 - 2mm
5
3
2
1
6
Side 2
2 - 3mm
Grind back Side 2 to sound metal and MPI
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
135 (MAG)
1.2
220 - 240
26 - 28
DC +ve
5.5 - 6.2
250 - 270
1.0 - 1.3
2-6
135 (MAG)
1.2
270 - 290
29 - 31
DC +ve
7.5 - 8.3
300 - 320
1.1 - 1.4
Argon / 20% CO2 / 2% O2
15 - 18 L/min
N/A
Grind back to sound metal and MPI
Preheat Temperature
0C Minimum
250C Maximum
N/A
N/A
N/A
Other Information:

For Manufacturer:
RWCs Signature
21

To be confirmed

Location: Workshop
WPQR: N/A*

BS EN 10025-2: S355 J2 (Max CEV = 0.45)
Welding Position: PC (Horizontal)

(full penetration, with permanent backing)
Joint Design
Backing material
25 x 6 mm
n
Welding Sequence
0 - 1mm
30 - 0 / +5
6
2 4
1 3 5
6 - 8mm
15 - 0 / +5
1mm
10mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
135 (MAG)
1.2
220 - 240
26 - 28
DC +ve
5.5 - 6.2
250 - 270
1.0 - 1.3
2-5
135 (MAG)
1.2
270 - 290
29 - 31
DC +ve
7.5 - 8.3
300 - 320
1.2 - 1.4
135 (MAG)
1.2
220 - 240
26 - 28
DC +ve
5.5 - 6.2
250 - 270
1.0 - 1.3
Argon / 20% CO2 / 2% O2
15 - 18 L/min
N/A
25mm x 6mm thick backing from S355 J2
Preheat Temperature
0C Minimum
250C Maximum
N/A
N/A
N/A
Other Information:

Backing material tack welded in position using parameters as for run number 1.
For Manufacturer:
RWCs Signature

To be confirmed
22

Location: Workshop
WPQR: N/A*

BS EN 10025-2: S355 J2 (Max CEV = 0.45)

(full penetration - with permanent backing)
Joint Design
Backing material
25 x 6 mm
Welding Sequence
6 - 8mm
10mm
< 1mm
0 - 1mm
2
3
40 - 0 / +10
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
135 (MAG)
1.2
170 - 190
19 - 21
DC +ve
4.8 - 5.5
120 - 140
1.1 - 1.6
2-3
135 (MAG)
1.2
170 - 190
19 - 21
DC +ve
4.8 - 5.5
100 - 120
1.2 - 1.9
Argon / 20% CO2 / 2% O2
15 - 18 L/min
N/A
Preheat Temperature
0C Minimum
250C Maximum
N/A
N/A
N/A
Other Information:

For Manufacturer:
RWCs Signature
23

To be confirmed

Location: Workshop
WPQR: N/A*

BS EN 10025-2: S355 J2 (Max CEV = 0.45)

Joint Design
Backing material
25 x 6 mm
Welding Sequence
0 - 1mm
30 - 0 / +5
2 4
1 3
6 - 8mm
15 - 0 / +5
7
6
5
< 1mm
15mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
135 (MAG)
1.2
220 - 240
26 - 28
DC +ve
5.5 - 6.2
250 - 270
1.0 - 1.3
2-6
135 (MAG)
1.2
270 - 290
29 - 31
DC +ve
7.5 - 8.3
300 - 320
1.2 - 1.4
135 (MAG)
1.2
220 - 240
26 - 28
DC +ve
5.5 - 6.2
250 - 270
1.0 - 1.3
Argon / 20% CO2 / 2% O2
15 - 18 L/min
N/A
Preheat Temperature
0C Minimum
250C Maximum
N/A
N/A
N/A
Other Information:

For Manufacturer:
RWCs Signature

To be confirmed
24

Location: Workshop
WPQR: N/A*

BS EN 10025-2: S355 J2 (Max CEV = 0.45)

Joint Design
Backing material
25 x 6 mm
Welding Sequence
6 - 8mm
15mm
< 1mm
1
2
3
4
0 - 1mm
40 - 0 / +10
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
135 (MAG)
1.2
170 - 190
19 - 21
DC +ve
4.8 - 5.5
120 - 140
1.1 - 1.6
2-4
135 (MAG)
1.2
170 - 190
19 - 21
DC +ve
4.8 - 5.5
100 - 120
1.2 - 1.9
Argon / 20% CO2 / 2% O2
15 - 18 L/min
N/A
Preheat Temperature
0C Minimum
250C Maximum
N/A
N/A
N/A
Other Information:

For Manufacturer:
RWCs Signature
25

To be confirmed
5 Qualification of Welding Procedure

Specifications
5.1
Introduction
The welding procedures presented in Section 4 are classified as

preliminary Welding Procedure Specifications (pWPS) by BS EN ISO
15614-1 and, as such, will require qualification prior to use. The
general rules for qualification of welding procedures are given in BS
EN ISO 15607. This allows qualification by a number of methods,
each having certain limits of application with respect to parent
material, consumables etc. The method generally adopted in the UK
is to carry out joint specific weld procedure tests and produce a
Welding Procedure Qualification Record (WPQR) in accordance with
the requirements of BS EN ISO 15614-1.
The WPQR is the document used to record all the necessary data for
qualification of the pWPS. It contains the actual welding parameters
used in the weld procedure test and the results of the required nondestructive and destructive tests. Satisfactory completion of a
WPQR turns the pWPS into a 'qualified' Welding Procedure
Specification (WPS). An example of a completed WPQR is given in
Appendix C of this document.
To minimise the number of weld procedure tests required, BS EN
ISO 15614-1 uses a limiting range of variables which allow the
steelwork contractor to produce a number of 'qualified' WPS from a
single WPQR. A company's Responsible Welding Coordinator
(RWC) will therefore carefully select the features of a weld procedure
test so that the resulting WPQR qualifies a wide range of WPS.
Sections 5.2 and 5.3 demonstrate the link between the pWPS in
Section 4 and the typical WPS contained in Section 6 which may be
qualified according to the standard.
Welding position
In accordance with the welding position and process specific
requirements of BS EN ISO 15614-1 (Sections 8.4.2 and 8.5.2), this
document recommends separate tests (pWPS 05p, 06p, 07p and
08p) to cover the PF positions.
Table 5.1 indicates the pWPS and consequent range of approval
based strictly on BS EN ISO 15614-1. It should be noted, however,
that achieving the 9mm maximum allowable leg length for single run
fillets may be impractical.
pWPS
01p
single run fillet, 4.5 - 9mm leg length,

5 - 12mm material, PB and PA position
02p

12.5 - 30mm material, PB and PA position
03p
multi-run fillet, unrestricted leg length,

5 - 12mm material, PB and PA position
04p

12.5 - 30mm material, PB and PA position
05p

5 - 12mm material, PF position
06p

12.5 - 30mm material, PF position
07p

5 - 12mm material, PF position
08p
5.2
Fillet welds
Clause 8.4.3 of BS EN ISO 15614-1 states that fillet welds can be

qualified by butt weld test pieces unless fillet welds are the
predominant form of production welding; in which case fillet weld
tests are required. Since fillet welds are considered to be the most
common form of weld used by UK steelwork contractors, it is
recommended that appropriate fillet weld qualification tests are
carried out.
Fillet welds are covered by pWPS 01p to 08p.
Fillet Weld Approval
12.5 - 30mm material, PF position

Table 5.1
5.3
Fillet weld pWPS and range of approval
Butt welds
In similar fashion to the fillet welds, the pWPS for butt welds have
been chosen to achieve approval over a range of material thickness,
and for a variety of weld types and positions. The pWPS for butt
welds are arranged as shown in Table 5.2, and the range of approval
described in the following sub-sections.
The pWPS have been selected to achieve approval over a range of

material thicknesses and fillet weld sizes in single and multiple runs.
pWPS Joint Type
Material thickness
The material thicknesses of 10 and 25mm cover thickness ranges of
5 to 12mm and 12.5 to 30mm respectively.
Material
Position Thickness
(mm)
09p
Single vee butt (welded from both sides)
PA
10
10p
Single vee butt (welded from both sides)
PA
15
The 6mm fillet covers single run fillets with leg lengths of 4.5 to 9mm.
11p
Single vee butt with backing
PC
10
The 10mm fillet covers multi-run fillets with no restriction on leg length.
12p
PC
15
13p
PF
10
14p
PF
15
Weld size
Table 5.2
Butt weld pWPS
26
Material thickness
The material thicknesses of 10 and 15mm cover thickness ranges of
3 to 12mm and 7.5 to 30mm respectively.
Welding position
BS EN ISO 15614-1 indicates that where neither impact nor
hardness requirements are specified, welding in any one position
qualifies for welding in all positions. In almost all instances, impact
requirements will have been specified by the choice of steel subgrade made by the structural designer. When either impact or
hardness requirements must be satisfied, the range of positions
approved is determined by the positions in which the weld
procedure test pieces were carried out and is related to the heat
input during welding. The range of positions approved are those with
heat inputs between the highest and lowest heat inputs tested.
pWPS 09p and 10p reflect the most straightforward type of butt
welding in the PA position and approval is limited to PA positions only.
To achieve a wider range of qualified positions, pWPS 11p to 14p are
completed in the PF and PC positions. PF is generally the highest
heat input position and PC the lowest, approving PA, PC and PF.
Joint type
Clause 8.4.3 of BS EN ISO 15614-1 specifies the range of
qualification for joint types. All the butt welds in this document are inline butt welds on plate. PWPS 09p and 10p are used to qualify the
butt welds covered in the Category 3 and 4 WPS (See Table 6.1).
These pWPS are welded from both sides with back gouging and / or
grinding and, as such, only qualify butt welds made from both sides
with back gouging and / or grinding. Single sided welds and those
with backing are not qualified.
Some of the butt welds in the Category 5 WPS (See Table 6.1) are
qualified by single sided butt welds made with permanent backing
(pWPS 11p to 14p). In accordance with BS EN ISO 15614-1, butt
welds with backing also qualify butt welds welded from both sides.
However, this document also recommends qualification of pWPS
09p and 10p when qualifying the Category 5 WPS so as to
demonstrate full positional capability.
In-line butt welds on plate also qualify T butt welds on plate.
However, it should be noted that T butt welds are generally
considered difficult to form and it may be advisable to carry out weld
procedure tests for T butt welds.
Welder approval
The procedure qualification tests in this document have been
chosen primarily to qualify the procedures, not the welders.
However, Clause 5 of BS EN ISO 15614-1 states that the welder who
undertakes the welding procedure test satisfactorily is qualified
within the range of qualification given in BS EN 287.
Material
It is recommended that the test material is BS EN 10025 - S355J2,
as successful tests in this material will also cover steels of lower yield
strength and those with lesser impact properties.
27
5.4
Examination and testing
The examination and testing requirements of the test pieces are

specified in Table 1 of BS EN ISO 15614-1. Clause 1 states that
additional tests may be specified by the relevant application
standard. Examples of the additional tests that may be required are
given in Clause 7.1 of BS EN ISO 15614-1. However, these are not
typically requested for structural steelwork used in buildings and
bridges and so are not covered in this document.
The range of welding positions qualified depends on heat input, as
described above. When a range of positional qualification is required
(as opposed to a single position) the specimens for impact tests
should be taken from the position with highest heat input (PF in this
document) and the specimens for the hardness tests taken from the
position with lowest heat input (PC in this document).
Additionally, impact tests are only required when the material
thickness is greater than 12mm, and thus if required, impact test
specimens should be taken from the weld procedure test in the
15mm material.
6 Typical Welding Procedure Specifications

This section contains 40 partially completed Welding Procedure
Specifications (WPS), described in this publication as "typical" WPS.
These may be completed and approved for use once the
appropriate welding procedure tests described have been
completed. Each WPS will be linked to one or more Welding
Procedure Qualification Record (WPQR).
should be dressed or thoroughly removed by grinding or gouging

such that subsequent welding is unaffected. Defective tack welds, or
tack welds made by a different procedure to the main weld must be
removed completely. Alternatively, those which are not defective may
be incorporated into main welds providing it is proven in the WPQR
that they are subsequently fully re-melted.
Section 4 describes the information shown on the preliminary
NDT
Welding Procedure Specifications. Much of this is repeated in the

typical WPS in this Section and the user should refer to Section 4.
The features of the WPS which differ from the pWPS are described
in the following paragraphs.
It is recommended that inspection and testing is carried out in

accordance with either the National Structural Steelwork
Specification (NSSS) 5th Edition or the new 'CE Marking' Edition, if
no alternative application standard is specified in the contract.
Welding procedure specification number
Weld finish
Procedures are presented in numerical order. The letters indicate the

welding position, as described in Section 4.1.
In all cases, this is stated as 'as-welded unless otherwise specified'.
Interpass temperature
A suffix (a, b or c) differentiates minor changes to essentially the
same procedure due to slight differences in preparation or welding
from one / both sides.
Welding procedure qualification record (WPQR)

number(s)
Each WPS is approved by one or more WPQR, which should
be referenced.
Weld preparation
The joint design sketches on the partial penetration butt weld WPS
in this document use the term 'design throat' as a means of
specifying the depth of preparation required. Whilst responsibility for
specifying the design throat thickness rests with the structural
designer, the steelwork contractor is responsible for selecting the
appropriate depth of preparation to ensure the required design
throat thickness (i.e. depth of penetration) is achieved.
Each WPS states interpass temperature as (C) 'maximum recorded

in WPQR'. Under normal circumstances, within the range of
materials and joint types used in this document, interpass
temperatures up to 250C are unlikely to be detrimental to the weld
quality or properties of the parent material. BS EN ISO 15614-1,
however, sets the upper limit of approval as the nominal maximum
interpass temperature reached during the welding procedure test.
Therefore, on satisfactory completion of the WPQR, the RWC is
required to record the actual value on the WPS.
For examiner / examining body

Whilst the steelwork contractor's RWC is required to sign and date
the WPS, there is no specific requirement in BS EN ISO 15614-1 for
the examiner / examining body to do so unless this is a specific
contract requirement. Each WPS therefore states 'N/A' (i.e. not
applicable).
Run
Where a weld can be completed within the same range of welding
parameters the term 'All' is used to show that there is no distinction
between passes. For those welds requiring the use of a broad range
of welding parameters, the welding runs are described as 'root' (the
first weld pass), 'fill' (all intermediate passes) and 'cap' (the final pass).
Welding details
The welding parameters, travel speeds, wire feed rates etc. shown
on the WPS are based on those used in the welding procedure test.
Each parameter will normally be quoted as a range (as specified in
BS EN ISO 15614-1), the mid-point being the nominal value
recorded during the test. The ranges shown on the partially
completed WPS indicate typical values, and will need to be replaced
with ranges based on the actual values recorded during the tests.
Tack welds
Tack welds (to maintain fit-up, or to attach backing strips) should be
made using the same parameters as for the first run of the main
welds. The length of the tack should be the lesser of 4 times the
thickness of the thicker part joined, or 50mm, unless demonstrated
in the WPQR that shorter lengths can be deposited without detriment
to the properties of the material and finished weld. Tack welds
28
Typical WPS - contents
6.1
Category
Approved Procedures
pWPS to
Procedure
be qualified
Joint Type
Preparation
Access
Page No
01-PA
10p
Single bevel butt (partial penetration)
single bevel
one side
29
01-PC
12p
single bevel
one side
30
01-PF
14p
single bevel
one side
31
02-PA
09p & 10p
Single bevel butt (full penetration)
single bevel
both sides
32
02-PC
12p
single bevel
both sides
33
02-PF
14p
single bevel
both sides
34
03-PA
09p & 10p
Single vee butt (partial penetration)
double bevel
one side
35
03-PF
14p
Single vee butt (partial penetration)
double bevel
one side
36
04-PA
09p & 10p
Single vee butt (full penetration)
double bevel
both sides
37
04-PF
14p
Single vee butt (full penetration)
double bevel
both sides
38
05-PA
13p & 14p
Single bevel butt (with backing)
single bevel
one side
39
05-PC
11p & 12p
single bevel
one side
40
05-PF
13p & 14p
single bevel
one side
41
06-PA
13p & 14p
Single vee butt (with backing)
double bevel
one side
42
06-PF
13p & 14p
Single vee butt (with backing)
double bevel
one side
43
07-PB(a)
01p & 02p
6, 8mm fillet
one side
44
07-PB(b)
03p & 04p
10, 12mm fillets
one side
45
07-PF(a)
05p & 06p
6, 8mm fillet
one side
46
07-PF(b)
07p & 08p
10, 12mm fillets
one side
47
08-PA
10p
Single bevel T butt (partial penetration)
single bevel
one side
48
08-PC
11p & 12p
single bevel
one side
49
08-PF
13p & 14p
single bevel
one side
50
09-PA
09p & 10p
Single bevel T butt (full penetration)
single bevel
both sides
51
09-PC
11p & 12p
single bevel
both sides
52
9-PF
13p & 14p
single bevel
both sides
53
10-PA
09p & 10p
Single bevel T butt
single bevel
both sides
54
10-PC
11p & 12p
Single bevel T butt
single bevel
both sides
55
10-PF
13p & 14p
Single bevel T butt
single bevel
both sides
56
Table 6.1
29
11-PC(a)
11p & 12p
Partial penetration butt
single bevel
one side
57
11-PC(b)
11p & 12p
single bevel
both sides
58
11-PC(c)
11p & 12p
Full penetration butt
single bevel
both sides
59
11-PF(a)
13p & 14p
single bevel
one side
60
11-PF(b)
13p & 14p
single bevel
both sides
61
11-PF(c)
13p & 14p
Full penetration butt
single bevel
both sides
67
12-PA(a)
09p & 10p
Double bevel T butt (partial penetration)
double bevel
both sides
63
12-PA(b)
09p & 10p
Double bevel T butt (full penetration)
double bevel
both sides
64
12-PC(a)
11p & 12p
double bevel
both sides
65
12-PC(b)
11p & 12p
double bevel
both sides
66
12-PF(a)
13p & 14p
double bevel
both sides
67
12-PF(b)
13p & 14p
double bevel
both sides
68
Typical WPS and pWPS to be qualified in order to support their approval
Welding Procedure Specification (WPS)

Location: Workshop
Manufacturers WPS No: 01-PA
WPQR: To be confirmed

BS EN 10025-2: S275 & S355 Up to and including sub-grade J2 (Max CEV = 0.45)
Material Thickness: 8 to 25mm
Welders Name: N/A

Joint Type: Single Bevel Butt Weld (partial penetration)
Joint Design
Welding Sequence
40 0 / +10
See Note 3
8 25 mm
0 3mm
See Note 2
D = Design Throa t
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
All
135 (MAG)
1.2
250 - 270
28 - 30
DC +ve
7.5 - 8.0
280 - 300
1.1 - 1.4
BS EN ISO 14341: G3Si1 (Trade name to be confirmed)
Argon / 20% CO2 / 2% O2
15 - 18 L/min
N/A
N/A
Preheat Temperature
0C Minimum (for combined thicknesses up to 50mm)
(C) maximum recorded in WPQR (Note 4)
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
For Manufacturer:
RWCs Signature

In all cases the gap between component parts shall be kept to a minimum.
Actual run sequence will depend on the thickness of the parent material; that shown is typical only.
Weld finish to be left as-welded unless specified otherwise.

N/A
30

Location: Workshop
Manufacturers WPS No: 01-PC

Material Thickness: 8 - 25mm
Welders Name: N/A

Joint Design
Welding Sequence
8 25 mm
D
See Note 3
40 0 / +10
0 3 mm
See Note 2
D = Design Throa t
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
Root
135
1.2
240 - 260
29 - 30
DC +ve
7.5 - 8.0
280 - 300
1.1 - 1.3
Fill
(Note 4)
135
1.2
270 - 290
29 - 30
DC +ve
8.5 - 9.0
300 - 320
1.2 - 1.4
Cap
135
1.2
240 - 260
29 - 30
DC +ve
7.5 - 8.0
280 - 300
1.1 - 1.3
Argon / 20% CO2 / 2% O2
15 - 18 L/min
N/A
N/A
Preheat Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
6.
For Manufacturer:
RWCs Signature
31

Material thickness may not always allow deposition of fill passes.
N/A

Location: Workshop
Manufacturers WPS No: 01-PF

Welders Name: N/A

Joint Design
Welding Sequence
D = Design Th roa t
0 3mm
See Note 2
See Note 3
8 25m m
40 0 / +10
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
All
135 (MAG)
1.2
160 - 180
22 - 24
DC +ve
3.5 - 4.0
150 - 210
0.8 - 1.4
Argon / 20% CO2 / 2% O2
15 - 18 L/min
N/A
N/A
Preheat Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
For Manufacturer:
RWCs Signature


N/A
32

Location: Workshop

Welders Name: N/A

Joint Type: Single Bevel Butt Weld (welded from both sides)
Joint Design
Welding Sequence
40 0 / +10
Side 1
See Note 3
See Note 2
5 25 mm
Cut back
Side 2
0 1 mm
0 3 mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
Root
135
1.2
220 - 240
26 - 28
DC +ve
5.5 - 6.0
300 - 360
0.75 - 1.0
Fill
(Note 4)
135
1.2
270 - 290
29 - 30
DC +ve
8.5 - 9.0
300 - 320
1.2 - 1.4
Cap &
Side 2
135
1.2
270 - 290
29 - 30
DC +ve
8.5 - 9.0
300 - 320
1.2 - 1.4
Argon / 20% CO2 / 2% O2
15 - 18 L/min
N/A
Arc air gouge and / or grind back Side 2 to sound metal
Preheat Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
6.
For Manufacturer:
RWCs Signature
33

For thicknesses >15mm, where access is not restricted, a double bevel preparation should be considered.

N/A

Location: Workshop

Welders Name: N/A

Joint Design
Welding Sequence
5 25 mm
Side 1
0 1mm
40 0 / +10
Side 2
Cut back
See Note 2
0 3mm
See Note 3
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
Root
135
1.2
220 - 240
26 - 28
DC +ve
5.5 - 6.0
300 - 360
0.75 - 1.0
Fill
(Note 4)
135
1.2
270 - 290
28 - 30
DC +ve
8.5 - 9.0
300 - 320
1.2 - 1.4
Cap &
Side 2
135
1.2
240 - 260
26 - 28
DC +ve
8.5 - 9.0
280 - 300
1.0 - 1.25
Argon / 20% CO2 / 2% O2
15 - 18 L/min
N/A
Preheat Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
6.
For Manufacturer:
RWCs Signature

N/A
34

Location: Workshop

Welders Name: N/A

Joint Design
0 3mm
Welding Sequence
Side 2
0 1mm
Cut back
See Note 3
See Note 2
5 25 mm
Side 1
40 0 / +10
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
All
135
1.2
160 - 180
22 - 24
DC +ve
3.5 - 4.0
150 - 210
0.8 - 1.4
Argon / 20% CO2 / 2% O2
15 - 18 L/min
N/A
Preheat Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
For Manufacturer:
RWCs Signature
35


N/A

Location: Workshop

Welders Name: N/A

Joint Type: Single Vee Butt Weld (partial penetration)
Joint Design
Welding Sequence
50 0 / +10
See Note 3
8 25 mm
0 3mm
See Note 2
D = Design Throa t
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
All
135 (MAG)
1.2
250 - 270
28 - 30
DC +ve
7.5 - 8.0
280 - 300
1.1 - 1.4
Argon / 20% CO2 / 2% O2
15 - 18 L/min
N/A
N/A
Preheat Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
For Manufacturer:
RWCs Signature


N/A
36

Location: Workshop

Welders Name: N/A

Joint Type: Single Vee Butt Weld (partial penetration)
Joint Design
Welding Sequence
D = Design Throa t
0 3 mm
See Note 2
8 25 mm
See Note 3
50 0 / +10
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
All
135 (MAG)
1.2
160 - 180
22 - 24
DC +ve
3.5 - 4.0
150 - 210
0.8 - 1.4
Argon / 20% CO2 / 2% O2
15 - 18 L/min
N/A
N/A
Preheat Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
For Manufacturer:
RWCs Signature
37


N/A

Location: Workshop

Welders Name: N/A

Joint Type: Single Vee Butt Weld (welded from both sides)
Joint Design
Welding Sequence
50 0 / +10
Side 1
See No te 2
See No te 3
5 25m m
Cut bac k
Side 2
0 1mm
0 3mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
Root
135
1.2
220 - 240
26 - 28
DC +ve
5.5 - 6.0
300 - 360
0.75 - 1.0
Fill
(Note 4)
135
1.2
270 - 290
29 - 30
DC +ve
8.5 - 9.0
300 - 320
1.2 - 1.4
Cap &
Side 2
135
1.2
270 - 290
29 - 30
DC +ve
8.5 - 9.0
300 - 320
1.2 - 1.4
Argon / 20% CO2 / 2% O2
15 - 18 L/min
N/A
Preheat Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
6.
For Manufacturer:
RWCs Signature

For thicknesses >15mm, where access is not restricted, a double vee preparation should be considered.
N/A
38

Location: Workshop

Welders Name: N/A

Joint Type: Single Vee Butt Weld (welded from both sides)
Joint Design
0 3mm
Welding Sequence
Side 2
0 1mm
Cut bac k
See No te 3
5 25m m
See No te 2
Side 1
50 0 / +10
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
All
135
1.2
160 - 180
22 - 24
DC +ve
3.5 - 4.0
150 - 210
0.8 - 1.4
Argon / 20% CO2 / 2% O2
15 - 18 L/min
N/A
Preheat Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
For Manufacturer:
RWCs Signature
39

For thicknesses >15mm, where access is not restricted, a double vee preparation should be considered.

N/A

Location: Workshop

Welders Name: N/A

Joint Type: Single Bevel Butt Weld (with permanent backing)
Joint Design
Welding Sequence
30 + / 5
6mm min.
See Note 4
5 25mm
0 1mm
0 1mm
See Note 2
See Note 3 regarding attachment of backing strip
See Note 5 regarding root deposition sequence
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
All
135
1.2
250 - 270
28 - 30
DC +ve
7.5 - 8.0
280 - 300
1.1 - 1.4
Argon / 20% CO2 / 2% O2
15 - 18 L/min
N/A
Nominal 25mm x 6mm S275 or S355 to suit parent material
Preheat Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
6.
7.
For Manufacturer:
RWCs Signature

In all cases the gap between the parent material and backing strip shall be kept to a minimum.
Permanent backing strip to be tack welded in position using the parameters given above.
For root gaps >8mm, 2 adjacent passes shall be deposited in the weld root.
N/A
40

Location: Workshop

Welders Name: N/A

Joint Design
Welding Sequence
5 25m m
See No te 4
0 1mm
30 + / 5
See Note 3 regarding

attachment of backing strip
6mm min.
See Note 5 regarding

root deposition
sequence
0 1mm
See Note 2
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
Root
135
1.2
240 - 260
29 - 30
DC +ve
7.5 - 8.0
280 - 300
1.1 - 1.3
Fill
(Note 4)
135
1.2
270 - 290
29 - 30
DC +ve
8.5 - 9.0
300 - 320
1.2 - 1.4
Cap
135
1.2
240 - 260
29 - 30
DC +ve
7.5 - 8.0
280 - 300
1.1 - 1.3
Argon / 20% CO2 / 2% O2
15 - 18 L/min
N/A
Preheat Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
6.
7.
For Manufacturer:
RWCs Signature
41

N/A

Location: Workshop

Welders Name: N/A

Joint Design
Welding Sequence
See No te 2
0 1mm
0 1mm
See No te 4
5 25m m
6mm min.
30 + / 5
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
All
135
1.2
160 - 210
22 - 24
DC +ve
3.5 - 4.0
150 - 210
0.8 - 1.4
Argon / 20% CO2 / 2% O2
15 - 18 L/min
N/A
Preheat Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
6.
7.
For Manufacturer:
RWCs Signature

N/A
42

Location: Workshop

Welders Name: N/A

Joint Type: Single Vee Butt Weld (with permanent backing)
Joint Design
Welding Sequence
40 0 / +10
6mm min.
See Note 4
5 25 mm
0 1mm
0 1mm
See Note 2
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
All
135
1.2
270 - 290
29 - 30
DC +ve
8.5 - 9.0
300 - 320
1.2 - 1.4
Argon / 20% CO2 / 2% O2
15 - 18 L/min
N/A
Preheat Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
6.
7.
For Manufacturer:
RWCs Signature
43

For root gaps greater >8mm, 2 adjacent passes shall be deposited in the weld root.
N/A

Location: Workshop

Welders Name: N/A

Joint Type: Single Vee Butt Weld (with permanent backing)
Joint Design
Welding Sequence

See Note 2
0 1mm
0 1mm
See Note 4
5 25 mm
6mm min.
40 0 / +10
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
All
135
1.2
160 - 180
22 - 24
DC +ve
3.5 - 4.0
150 - 210
0.8 - 1.4
Argon / 20% CO2 / 2% O2
15 - 18 L/min
N/A
Preheat Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
6.
7.
For Manufacturer:
RWCs Signature

N/A
44

Location: Workshop
Manufacturers WPS No: 07-PB(a)

Welding Position: PB (Horizontal / Vertical)
Welders Name: N/A

Joint Design
Welding Sequence
6 - 25mm
z68
See Notes 2 & 3
< 1mm
6 - 25mm

Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
All
135 (MAG)
1.2
270 - 290
29 - 31
DC +ve
7.5 - 8.0
320 - 340
1.1 - 1.3
Argon / 20% CO2 / 2% O2
15 - 18 L/min
N/A
N/A
Preheat Temperature
N/A
N/A
N/A
N/A
Other Information:
1. Nozzle diameter = 16mm.

2. In all cases the gap between component parts shall be kept to a minimum.
3. Should the gap between component parts exceed 1mm, the fillet leg length shall be increased in order
to achieve the required design throat thickness. Under no circumstance should the gap between component
parts exceed 3mm.
4. Weld finish to be left as-welded unless specified otherwise.
For Manufacturer:
RWCs Signature
45

N/A

Location: Workshop
Manufacturers WPS No: 07-PB(b)

Welding Position: PB (Horizontal / Vertical)
Welders Name: N/A

Joint Type: Multi-run Fillet Weld (Single or Double Sided)
Joint Design
Welding Sequence
6 - 25mm
z 10 12
3
See Notes 2 & 3
< 1.5mm
6 - 25mm

Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
135 (MAG)
1.2
270 - 290
29 - 31
DC +ve
7.5 - 8.0
280 - 300
1.1 - 1.3
2-3
135 (MAG)
1.2
250 - 270
26 - 28
DC +ve
6.0 - 6.5
260 - 280
1.1 - 1.4
Argon / 20% CO2 / 2% O2
15 - 18 L/min
N/A
N/A
Preheat Temperature
(C) maximum recorded in WPQR (See Note 4)
N/A
N/A
N/A
Other Information:

3. Should the gap between component parts exceed 1.5mm, the fillet leg length shall be increased in order
parts exceed 3mm.
4. Interpass temperature shall be checked using a contact thermometer or temperature indicating crayon.
For Manufacturer:
RWCs Signature

N/A
46

Location: Workshop
Manufacturers WPS No: 07-PF(a)

Welders Name: N/A

Joint Design
<1mm
Welding Sequence
6 - 25mm
See Notes 2 & 3
z68
6 - 25mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
135 (MAG)
1.2
170 - 190
22 - 24
DC +ve
4.0 - 4.5
120 - 160
1.1 - 1.8
Argon / 20% CO2 / 2% O2
15 - 18 L/min
N/A
N/A
Preheat Temperature
N/A
N/A
N/A
N/A
Other Information:

3. Should the gap between component parts exceed 1mm, the fillet leg length shall be increased in order
parts exceed 3mm.
For Manufacturer:
RWCs Signature
47

N/A

Location: Workshop
Manufacturers WPS No: 07-PF(b)

Welders Name: N/A

Joint Type: Multi-run Fillet Weld (Single or Double Sided)
Joint Design
Welding Sequence
10 - 25mm
<1.5mm
See Notes 2 & 3
1
3
z 10 12
10 - 25mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
1-3
135 (MAG)
1.2
170 - 190
22 - 24
DC +ve
4.0 - 4.5
120 - 160
1.1 - 1.8
Argon / 20% CO2 / 2% O2
15 - 18 L/min
N/A
N/A
Preheat Temperature
250 Maximum (See Note 4)
N/A
N/A
N/A
Other Information:

3. Should the gap between component parts exceed 1.5mm, the fillet leg length shall be increased
in order to achieve the required design throat thickness. Under no circumstance should the gap between
component parts exceed 3mm.
For Manufacturer:
RWCs Signature

N/A
48

Location: Workshop

Welders Name: N/A

Joint Type: Single Bevel Tee Butt Weld (partial penetration)
Joint Design
Welding Sequence
45 0 / +10
See Note 3
D
8 25m m
0 3mm
See Note 4
See Note 2
8 25mm
D = Design Th roa t
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
All
135 (MAG)
1.2
250 - 270
28 - 30
DC +ve
7.5 - 8.0
280 - 300
1.1 - 1.4
Argon / 20% CO2 / 2% O2
15 - 18 L/min
N/A
N/A
Preheat Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
6.
For Manufacturer:
RWCs Signature
49

This type of joint might typically be accompanied by a fillet weld on the reverse side.

N/A

Location: Workshop

Welders Name: N/A

Joint Design
Welding Sequence
D = Design Throa t
8 25mm
D
See Note 3
45 0 / +10
See Note 4
0 3mm
See Note 2
8 25mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
Root
135
1.2
240 - 260
29 - 30
DC +ve
7.5 - 8.0
280 - 300
1.1 - 1.3
Fill
(Note 4)
135
1.2
270 - 290
29 - 30
DC +ve
8.5 - 9.0
300 - 320
1.2 - 1.4
Cap
135
1.2
240 - 260
29 - 30
DC +ve
7.5 - 8.0
280 - 300
1.1 - 1.3
Argon / 20% CO2 / 2% O2
15 - 18 L/min
N/A
N/A
Preheat Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
6.
For Manufacturer:
RWCs Signature

N/A
50

Location: Workshop

Welders Name: N/A

Joint Design
Welding Sequence
8 25mm
See Note 4
0 3mm
See Note 2
8 25mm
D
See Note 3
45 0 / +10
D = Design Th roa t
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
All
135 (MAG)
1.2
170 - 190
22 - 24
DC +ve
3.5 - 4.0
120 - 160
1.1 - 1.8
Argon / 20% CO2 / 2% O2
15 - 18 L/min
N/A
N/A
Preheat Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
6.
For Manufacturer:
RWCs Signature
51

N/A

Location: Workshop

Welders Name: N/A

Joint Type: Single Bevel Tee Butt Weld (full penetration)
Joint Design
Welding Sequence
8 25mm
Side 1
45 0 / +10
See Note 3
See Note 2
8 25mm
0 1 mm
Side 2
0 3 mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
Root
135
1.2
260 - 280
26 - 28
DC +ve
5.5 - 6.0
240 - 285
1.1 - 1.5
Fill
(Note 4)
135
1.2
270 - 290
29 - 30
DC +ve
8.5 - 9.0
300 - 320
1.2 - 1.4
Cap &
Side 2
135
1.2
270 - 290
29 - 30
DC +ve
8.5 - 9.0
300 - 320
1.2 - 1.4
Argon / 20% CO2 / 2% O2
15 - 18 L/min
N/A
Arc air gouge and / or grind back Side 2 to sound metal.
Preheat Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
6.
For Manufacturer:
RWCs Signature

N/A
52

Location: Workshop

Welders Name: N/A

Joint Design
Welding Sequence
8 25mm
See Note 2
0 1mm
Side 2
45 0 / +10
0 3mm
Side 1
See Note 3
8 25mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
Root
135
1.2
260 - 280
26 - 28
DC +ve
5.5 - 6.0
240 - 285
1.1 - 1.5
Fill
(Note 4)
135
1.2
270 - 290
29 - 30
DC +ve
8.5 - 9.0
300 - 320
1.2 - 1.4
Cap &
Side 2
135
1.2
270 - 290
29 - 30
DC +ve
8.5 - 9.0
300 - 330
1.1 - 1.4
Argon / 20% CO2 / 2% O2
15 - 18 L/min
N/A
Preheat Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
6.
For Manufacturer:
RWCs Signature
53

N/A

Location: Workshop

Welders Name: N/A

Joint Design
Welding Sequence
0 1 mm
Side 2
0 3 mm
Cut back
See Note 2
8 25mm
See Note 3
45 0 / +10
Side 1
8 25mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
All
135 (MAG)
1.2
170 - 190
22 - 24
DC +ve
4.0 - 4.5
120 - 160
1.1 - 1.8
Argon / 20% CO2 / 2% O2

15 - 18 L/min

N/A
Preheat Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
For Manufacturer:
RWCs Signature


N/A
54

Location: Workshop

Welders Name: N/A

Joint Type: Single Bevel Tee Butt Weld (full strength)
Joint Design
Welding Sequence
8 25 mm
Side 1
45 0 / +10
See Note 3
See No te 2
8 25 mm
0 1mm
Side 2
0 3mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
Root
135
1.2
260 - 280
26 - 28
DC +ve
5.5 - 6.0
240 - 285
1.1 - 1.5
Fill
(Note 4)
135
1.2
270 - 290
29 - 30
DC +ve
8.5 - 9.0
300 - 320
1.2 - 1.4
Cap &
Side 2
135
1.2
270 - 290
29 - 30
DC +ve
8.5 - 9.0
300 - 320
1.2 - 1.4
Argon / 20% CO2 / 2% O2
15 - 18 L/min
N/A
N/A
Preheat Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
6.
For Manufacturer:
RWCs Signature
55

N/A

Location: Workshop

Welders Name: N/A

Joint Type: Single Bevel Tee Butt Weld (full strength)
Joint Design
Welding Sequence
8 25mm
See Note 2
0 1 mm
45 0/ +10
0 3 mm
Side 2
Side 1
See Note 3
8 25mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
Root
135
1.2
260 - 280
26 - 28
DC +ve
5.5 - 6.0
240 - 285
1.1 - 1.5
Fill
(Note 4)
135
1.2
270 - 290
29 - 30
DC +ve
8.5 - 9.0
300 - 320
1.2 - 1.4
Cap &
Side 2
135
1.2
270 - 290
29 - 30
DC +ve
8.5 - 9.0
300 - 330
1.1 - 1.4
Argon / 20% CO2 / 2% O2
15 - 18 L/min
N/A
N/A
Preheat Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
6.
For Manufacturer:
RWCs Signature

N/A
56

Location: Workshop

Welders Name: N/A

Joint Design
Welding Sequence
0 1 mm
0 3 mm
See Note 2
8 25 mm
See Note 3
45 0 / +10
8 25mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
All
135 (MAG)
1.2
170 - 190
22 - 24
DC +ve
4.0 - 4.5
120 - 160
1.1 - 1.8
Argon / 20% CO2 / 2% O2
15 - 18 L/min
N/A
N/A
Preheat Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
For Manufacturer:
RWCs Signature
57


N/A

Location: Workshop
Manufacturers WPS No: 11-PC(a)

Welders Name: N/A

Joint Type: Partial Penetration Butt (welded from one side)
Joint Design
Welding Sequence
8 25 mm
See Note 2
45 0/ +10
0 3 mm
See Note 3
8 25 mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
All
135 (MAG)
1.2
250 - 270
28 - 30
DC +ve
7.5 - 8.0
280 - 300
1.1 - 1.4
Argon / 20% CO2 / 2% O2
15 - 18 L/min
N/A
N/A
Preheat Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
For Manufacturer:
RWCs Signature

The maximum unfused root = 3mm

N/A
58

Location: Workshop
Manufacturers WPS No: 11-PC(b)

Welders Name: N/A

Joint Type: Partial Penetration Butt (welded from both sides)
Joint Design
Welding Sequence
8 25 mm
See Note 2
45 0/ +10
Min 35 for access
0 3 mm
See Note 3
8 25 mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
All
135 (MAG)
1.2
250 - 270
28 - 30
DC +ve
7.5 - 8.0
280 - 300
1.1 - 1.4
Argon / 20% CO2 / 2% O2
15 - 18 L/min
N/A
N/A
Preheat Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
For Manufacturer:
RWCs Signature
59


N/A

Location: Workshop
Manufacturers WPS No: 11-PC(c)

Welders Name: N/A

Joint Type: Full Penetration Butt (welded from both sides)
Joint Design
Welding Sequence
8 25mm
See No te 3
Cut back
45 0/ +10
Min 35 for access
Side 1
0 3 mm
Side 2
See Note 2
8 25mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
All
135 (MAG)
1.2
250 - 270
28 - 30
DC +ve
7.5 - 8.0
280 - 300
1.1 - 1.4
Argon / 20% CO2 / 2% O2
15 - 18 L/min
N/A
Preheat Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
For Manufacturer:
RWCs Signature

It is permissible to weld Side 2 first and cut back to sound metal from Side 1.

N/A
60

Location: Workshop

Welders Name: N/A

Joint Type: Partial Penetration Butt (welded from one side)
Joint Design
8 25 mm
Welding Sequence
0 3mm
See Note 3
45 0/ +10
See Note 2
8 25 mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
All
135 (MAG)
1.2
170 - 190
22 - 24
DC +ve
4.0 - 4.5
120 - 160
1.1 - 1.8
Argon / 20% CO2 / 2% O2
15 - 18 L/min
N/A
N/A
Preheat Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
For Manufacturer:
RWCs Signature
61


N/A

Location: Workshop

Welders Name: N/A

Joint Type: Partial Penetration Butt (welded from both sides)
Joint Design
8 25 mm
Welding Sequence
0 3mm
See Note 3
45 0 / +10
Min 35 for access
See Note 2
8 25 mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
All
135 (MAG)
1.2
170 - 190
22 - 24
DC +ve
4.0 - 4.5
120 - 160
1.1 - 1.8
Argon / 20% CO2 / 2% O2
15 - 18 L/min
N/A
N/A
Preheat Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
For Manufacturer:
RWCs Signature


N/A
62

Location: Workshop
Manufacturers WPS No: 11-PF(c)

Welders Name: N/A

Joint Type: Full Penetration Butt (welded from both sides)
Joint Design
8 25 mm
Welding Sequence
0 3 mm
See Note 2
Side 1
Side 2
45 0 / +10
Min 35 for access
Cut back
See Note 3
8 25mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
All
135 (MAG)
1.2
170 - 190
22 - 24
DC +ve
4.0 - 4.5
120 - 160
1.1 - 1.8
Argon / 20% CO2 / 2% O2
15 - 18 L/min
N/A
Preheat Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
For Manufacturer:
RWCs Signature
63

It is permissible to weld Side 2 first and cut back to sound metal from Side 1.

N/A

Location: Workshop
Manufacturers WPS No: 12-PA(a)

Welders Name: N/A

Joint Type: Double Bevel Tee Butt Weld (partial penetration)
Joint Design
Welding Sequence
0 3 mm
See Note 2
=
8 25mm
See Notes
4&5
=
45 0 / +10 Typical
See Note 3 regarding depth of preparation
8 25 mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
All
135 (MAG)
1.2
250 - 270
28 - 30
DC +ve
7.5 - 8.0
280 - 300
1.1 - 1.4
Argon / 20% CO2 / 2% O2
15 - 18 L/min
N/A
N/A
Preheat Temperature
N/A
N/A
N/A
Other Information:

3. The depth of preparation shall be such that the deposited weld will satisfy the required design throat thickness.
4. Actual run sequence will depend on the thickness of the parent material; that shown is typical only.
5. A balanced welding sequence may be required to avoid distortion; particularly in the thicker material ranges.
For Manufacturer:
RWCs Signature

N/A
64

Location: Workshop
Manufacturers WPS No: 12-PA(b)

Welders Name: N/A

Joint Type: Double Bevel Tee Butt Weld (full penetration)
Joint Design
Welding Sequence
0 3mm
Side 1
=
8 25 mm
See Notes
2&3
0 2mm
Cut back
Side 2
45 0 / +10 Typical
8 25 mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
All
135 (MAG)
1.2
250 - 270
28 - 30
DC +ve
7.5 - 8.0
280 - 300
1.1 - 1.4
Argon / 20% CO2 / 2% O2
15 - 18 L/min
N/A
Preheat Temperature
N/A
N/A
N/A
Other Information:

2. Actual run sequence will depend on the thickness of the parent material; that shown is typical only.
3. A balanced welding sequence may be required to avoid distortion; particularly in the thicker material ranges.
For Manufacturer:
RWCs Signature
65

N/A

Location: Workshop
Manufacturers WPS No: 12-PC(a)

Welders Name: N/A

Joint Design
Welding Sequence
8 25mm
0 3 mm
45 0 / +10 Typical
See Note 2
See Notes
4&5
8 25mm

Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
Root
135
1.2
260 - 280
26 - 28
DC +ve
5.5 - 6.0
240 - 285
1.1 - 1.5
Fill
135
1.2
270 - 290
29 - 30
DC +ve
8.5 - 9.0
300 - 320
1.2 - 1.4
Cap
135
1.2
270 - 290
29 - 30
DC +ve
8.5 - 9.0
300 - 330
1.1 - 1.4
Argon / 20% CO2 / 2% O2
15 - 18 L/min
N/A
N/A
Preheat Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
6.
7.
For Manufacturer:
RWCs Signature

The depth of preparation shall be such that the deposited weld will satisfy the required design throat thickness.
A balanced welding sequence may be required to avoid distortion; particularly in the thicker material ranges.
N/A
66

Location: Workshop
Manufacturers WPS No: 12-PC(b)

Welders Name: N/A

Joint Design
Welding Sequence
8 25 mm
=
Side 1
0 3mm
Cut back
Side 2
45 0 / +10 Typical
See Notes
2&3
8 25 mm
0 2mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
Root
135
1.2
260 - 280
26 - 28
DC +ve
5.5 - 6.0
240 - 285
1.1 - 1.5
Fill
(Note 4)
135
1.2
270 - 290
29 - 30
DC +ve
8.5 - 9.0
300 - 320
1.2 - 1.4
Cap
135
1.2
270 - 290
29 - 30
DC +ve
8.5 - 9.0
300 - 330
1.1 - 1.4
Argon / 20% CO2 / 2% O2
15 - 18 L/min
N/A
Preheat Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
For Manufacturer:
RWCs Signature
67


N/A

Location: Workshop

Welders Name: N/A

Joint Design
Welding Sequence
8 25 mm
0 3 mm
See Note 2
45 0 / +10 Typical
See Notes
4&5
8 25 mm

Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
All
135 (MAG)
1.2
170 - 190
22 - 24
DC +ve
4.0 - 4.5
120 - 160
1.1 - 1.8
Argon / 20% CO2 / 2% O2
15 - 18 L/min
N/A
N/A
Preheat Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
6.
7.
For Manufacturer:
RWCs Signature

The depth of preparation shall be such that the deposited weld will satisfy the required design throat thickness.
N/A
68

Location: Workshop

Welders Name: N/A

Joint Design
0 2 mm
0 3 mm
Welding Sequence
See Notes
2&3
8 25 mm
45 0 / +10 Typical
Side 1
Side 2
Cut back
8 25 mm
Welding Details:
Run
Process
Size of
Filler Metal
mm
Current
A
Voltage
V
Type of
Current/
Polarity
Wire Feed
Speed
m/min
Travel
Speed
mm/min
Heat
Input
kJ/mm
All
135 (MAG)
1.2
170 - 190
22 - 24
DC +ve
4.0 - 4.5
120 - 160
1.1 - 1.8
Argon / 20% CO2 / 2% O2
15 - 18 L/min
N/A
Preheat Temperature
N/A
N/A
N/A
Other Information:
1.
2.
3.
4.
5.
For Manufacturer:
RWCs Signature
69


N/A
7 References
BSI Publications:
BS EN ISO 15614-1: Specification and qualification of welding procedures for metallic materials - Welding procedure test - Part 1: Arc and gas
welding of steels and arc welding of nickel and nickel alloys
BS EN 287-1:
Qualification test of welders - Fusion welding - Part 1: Steels
BS EN 1011-1:
Welding - Recommendations for welding of metallic materials - Part 1: General guidance for arc welding
BS EN 1011-2:
Welding - Recommendations for welding of metallic materials - Part 2: Arc welding of ferritic steels
BS EN ISO 15609-1: Specification and qualification of welding procedures for metallic materials - Welding procedure specification - Part 1:
Arc welding
BS EN 10025-1:
Hot rolled products of structural steels - Part 1: General technical delivery conditions
BS EN 10025-2:
Hot rolled products of structural steels - Part 2: Technical delivery conditions for non-alloy structural steels
BS EN ISO 3690:
Welding and allied processes - Determination of hydrogen content in ferritic steel arc weld metal
BS EN ISO 6947:
Welds - Working positions - Definitions of angles of slope and rotation
BS EN ISO 9692:
Welding and allied processes - Recommendations for joint preparation - Part 1: Manual metal-arc welding, gas-shielded
metal-arc welding, gas welding, TIG welding and beam welding of steels
BS EN ISO 4063:
Welding and allied processes - Nomenclature of processes and reference numbers
BS EN ISO 14341:
Welding consumables - Wire electrodes and deposits for gas shielded metal arc welding of non alloy and fine grain steels
- Classification
BS 2901:
Filler rods and wires for gas-shielded arc welding - Part 1: Ferritic steels
BS EN ISO 14175:
Welding consumables - Gases and gas mixtures for fusion welding
BS EN ISO 15607:
Specification and qualification of welding procedures for metallic materials - General rules
BCSA Publications:
National Structural Steelwork Specification - 5th Edition
National Structural Steelwork Specification - CE Marking Edition
70
Appendix A - Calculation of preheating

requirements
200
The following example demonstrates the calculation of pre-heat

requirement for the procedures in this publication.
180
Assuming a T type joint (fillet or butt), using 25mm thick plate

(Figure A1):
Combined thickness (mm)
160
All plate 25mm
140
125
100
Minimum preheating
temperature, C
50 0
75 20
120
100
80
60
40
20
Figure A1: T type joint
0
0,0
0,5
1,0
The combined thickness as determined in Figure C.1 in BS EN

1011-2 is 75mm (Figure A2):
Hydrogen Scale
d3
To be used for carbon

equivalent not exceeding
d1
d2 (= d1)
Combined Thickness = d1 + d2+ d3

Figure A2: Determination of combined thickness
In accordance with BS EN 1011-2, Section C.2.3.3, solid wires for

gas shielded arc welding may be used with a hydrogen scale D.
With a combined thickness of 75mm and hydrogen scale D, in

accordance with BS EN 1011-2 Figure C.2 b) the minimum
allowable heat input without preheat is ~1.1 kJ/mm (Figure A3).
2,5
3,0
0,34
0,39
0,41
0,46
0,48
All rust, paint, grease and moisture should be removed from the
workpiece if hydrogen scale D is to be achieved. Should any of
these contaminants be present, the hydrogen scale would have
to be increased to scale B; which requires the use of Figure C.2
e) of BS EN 1011-2 (Figure A4). Using the same key parameters
(i.e. CEV, combined thickness and a 1.1 kJ/mm heat input)
preheating to a minimum of 125C is required. Procedures
requiring preheat are outside the scope of this publication.
200
Minimum preheating temperature, C
180
160
Combined thickness (mm)
In the absence of specific material certification, a Carbon

Equivalent Value (CEV) of 0.45 has been selected. This is based
on the maximum allowable in BS EN 10025 - 2 for grade S355
material < 30mm thick.
2,0
Figure A3: BS EN 1011-2 Figure C.2 b)
1,5
Heat Input (kJ/mm)
175
150
125
100
75
50
20
140
120
100
80
60
40
20
0
0,0
0,5
1,0
1,5
2,0
2,5
3,0
3,5
4,0
Heat Input (kJ/mm)
Hydrogen Scale
To be used for carbon
equivalent not exceeding
0,43
0,45
0,47
0,53
0,55
Figure A4: BS EN 1011-2 Figure C.2 e)
71
4,5
Appendix B - Metal-arc Active Gas shielded

(MAG) welding with solid wire (Process 135)
The number of combinations of wire diameter and shielding gas
composition for this process is considerable. The typical WPS in this
document incorporate the most commonly used shielding gas
composition and a wire size (1.2 mm diameter) which is sufficiently
small to produce well controlled weld roots and positional beads whilst
being large enough to generate acceptable deposition rates in the
flat (PA) position. Although welds can be produced over a range of
parameters, the lack of flux to act as an arc stabiliser and wetting agent
means that this form of welding is more sensitive to deviations from
optimum parameters than most others. Consequently, additional care
should be taken with the selection of parameters and monitoring of
these with the bead profile. Parameters not correctly set, incorrect
technique or improperly adjusted or worn equipment, can usually be
identified firstly by the amount of spatter produced and secondly by a
poor bead appearance. However, good bead appearance is not a
guarantee of good quality, and may conceal sub-surface imperfections.
MAG welding is a partly mechanised semi-automatic welding process
that is now commonly introduced into the workshop as a replacement
for manual metal arc welding. However, the equipment used is far more
sophisticated and more complex to operate, and without correct
installation and maintenance, weld quality and production rates are
likely to suffer. The required routine maintenance should therefore not
be neglected and operators should receive appropriate training. As
with all partly mechanised semi-automatic arc welding processes,
consistent wire feed (which is achieved by use of correct feed rolls,
contact tips and nozzles), is essential. Insufficient gas coverage is
another common cause of poor weld appearance and care should be
taken to ensure that the gas flow indicated by the flow meter is being
delivered to the nozzle, and that spatter inside the nozzle is not causing
the emergent gas to swirl and so draw in air. Draughts can also disturb
the shielding gas and may result in embrittlement and porosity.
Excessive contact tip wear, giving poor wire contact, can result in
intermittent arcing and unstable welding conditions. The tip should be
replaced before this stage is reached.
Two conventional operating modes can be used for welding,
depending on the workpiece thickness and welding position. At high
currents a characteristic spray mode of metal transfer is generated in
which a spray of fine metallic droplets is propelled across the arc in a
stable manner. This spray transfer mode provides high weld deposition
rates with deeply penetrating arc characteristics making it suitable for
producing fully fused welds in relatively thick sections (usually 6mm
and upwards). For a solid wire of 1.2mm diameter, spray transfer
welding may be accomplished using welding current in the range 250400A and Voltage of 26-35V, depending on the shielding gas
composition used. The spray transfer mode is appropriate for use in
the PA and PB positions.
The dip transfer or short circuiting arc mode is appropriate for welding
in all positions. Low current and voltage settings produce a short
circuiting arc to achieve controlled transfer of metal droplets.
This mode is associated with low heat input. Precise control of the
parameter settings is required to attain stable operating conditions and
to avoid lack of fusion defects. For a solid wire of 1.2mm diameter, a
current range of 80-200A and a voltage range of 15-23V can be used.
In addition, it may be necessary to set the inductance or choke level of
the equipment. This slows down the surge in current when short
circuiting takes place and reduces spatter.
Useful generalisations in setting up and operating solid wire
semi-automatic equipment are set out below (see Figure B.1):
1. Constant voltage (flat characteristic power curve) DC power
source is preferred;
2. Two or four roll feeders can be used but care should be taken to
ensure that their alignment is accurate;
3. For spray transfer mode, an electrode extension of 15-20mm is
typical, with the contact tip retracted 3mm within the gas nozzle;
4. For dip transfer mode, an electrode extension of 6-12mm is typical,
with the contact tip extended 3mm outside the gas nozzle;
5. A gas nozzle of 16mm diameter is generally used;
6. The preferred torch angles depend on welding position being
used. The suggested ranges and directions are as follows:
Transfer
Mode
Welding
Postion
Angle of torch in
and direction
Spray
PA, PB, PC
Dip
PF
0 - 5 Trailing
Dip
All except PF
15 - 20 Leading or Trailing
10-20
(1)
Leading
Note 1: For a flat bead, 5 - 10 is appropriate.

Lead
angle
Nozzle
Contact
tip
Trail
angle
Nozzle
Completed weld
Direction of travel
This section offers guidance on welding process 135 - metal-arc active

gas welding, commonly known as MAG welding.
Contact tip
Completed weld
Direction of travel
PA Position
PF Position
Figure B.1 Typical torch to workpiece positions
72
Appendix C - Typical Welding Procedure

Qualification Record
73
74
75
Typical Welding Procedure Specifications

for Structural Steelwork

BS EN Welding Book

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Typical Welding

BCSA Publication No. 50/09

BCSA Publication No. 50/09

The British Constructional

TYPICAL WELDING PROCEDURE SPECIFICATIONS FOR STRUCTURAL STEELWORK

4 Preliminary Welding Procedure Specifications (pWPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

6 Typical Welding Procedure Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

TYPICAL WELDING PROCEDURE SPECIFICATIONS FOR STRUCTURAL STEELWORK

TYPICAL WELDING PROCEDURE SPECIFICATIONS FOR STRUCTURAL STEELWORK

Restriction on the CEV, material thickness and hydrogen Scale D

TYPICAL WELDING PROCEDURE SPECIFICATIONS FOR STRUCTURAL STEELWORK

3 Typical Welding Procedures

Steelwork contractors have, traditionally, tended to develop and

a broad range of welds may be covered by a few carefully

these procedures may be qualified using a limited range of

standard weld preparations in terms of included angle, root

when the weld preparations are standard, the chances of

use of standard welding conditions generates consistent

This document is aimed at providing the framework for a steelwork

Basis of the system

Qualification of Welding Procedure

This document is intended to assist steelwork contractors to develop

The system of preliminary Welding Procedure Specifications (pWPS)

Choose the appropriate

Details of required test

The joint details have been so arranged such that up to a specified

Figure 3.1 Method of qualifying welding procedures to

TYPICAL WELDING PROCEDURE SPECIFICATIONS FOR STRUCTURAL STEELWORK

How to use this document

A steelwork contractor using this document should:

01p, 02p, 03p, 04p

3. Collate and review the mechanical and non-destructive testing

01p, 02p, 03p, 04p,

Fillet welds only in PA, PB and

05p, 06p, 07p, 08p

01p, 02p, 03p, 04p

Fillet welds in PA and PB

Two sided butt welds in the

01p, 02p, 03p, 04p,

Fillet welds in PA, PB and PF

05p, 06p, 07p, 08p

Two sided butt welds in the

01p, 02p, 03p, 04p,

Fillet welds in PA, PB and PF

05p, 06p, 07p, 08p

Two sided butt welds in the

11p, 12p, 13p, 14p

Butt welds with backing in PC

Table 3.1 Category, pWPS and qualification range

2. Using the pWPS identified within the chosen category in Table

TYPICAL WELDING PROCEDURE SPECIFICATIONS FOR STRUCTURAL STEELWORK

4 Preliminary Welding Procedure

If a steelwork contractor's normal procedure is to weld materials which

Parent material designation

BS EN 10025 S355J2 steel with a maximum Carbon Equivalent

Weld Type Position

Method of preparation and cleaning

Table 4.1 Comparison of BS EN and AWS weld position

TYPICAL WELDING PROCEDURE SPECIFICATIONS FOR STRUCTURAL STEELWORK

A sketch of the welding sequence is given. This shows the intended

Size of filler metal

Filler metal classification and trade name

The consumable classification given in the pWPS is BS EN ISO

Any special baking or drying